Vehicle reservoir tank system

ABSTRACT

A vehicle reservoir tank includes first and second end walls, first and second side walls, upper and lower walls, and a projection. A fluid port is formed in a lower end of the first end wall. The first and second side walls extend between the first and second end walls to form a substantially rectangular configuration. The upper and lower walls extend between the first and second end walls and the first and second side walls to form a main reservoir chamber with an overflow port formed in the upper wall adjacent the second end wall. The projection extends into the main reservoir chamber from one of the lower wall and the second end wall. The projection is configured and arranged to redirect a fluid flowing into the main reservoir chamber from the fluid port in a direction away from the overflow port.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to a vehicle reservoir tank. More specifically, the present invention relates to a vehicle reservoir tank that prevents spilling of fluid from the vehicle reservoir tank during filling of vehicle cooling circuit with fluid.

2. Background Information

Currently, most automotive vehicles use a “water cooled” internal combustion engine. Typically, an engine coolant (liquid) is forcefully circulated by a water pump through a cooling circuit that includes an engine coolant jacket of the engine and an air cooled radiator. The cooling circuit is also typically provided with a vehicle reservoir tank, which is fluidly connected to the radiator. The radiator provides the engine coolant to the engine. The vehicle reservoir tank acts as an overflow tank of the engine coolant jacket and radiator combination. Thus, the vehicle reservoir tank can receive excess fluid (e.g. due to thermal expansion or the like) from the radiator. The vehicle reservoir tank can also be used to add coolant (liquid) to the cooling circuit, if needed. The vehicle reservoir tank has an overflow port to allow excess coolant (liquid) to flow out of the cooling circuit (e.g. if the cooling circuit is over-filled with coolant).

The cooling circuit is typically filled with coolant (liquid) during manufacture of the vehicle. In order to fill the cooling circuit with coolant, a fill opening of the radiator is injected with the coolant at high pressure. During this high pressure filling of the cooling circuit, coolant is injected into the vehicle reservoir tank from the radiator at relatively high pressure. This relatively high pressure fluid flowing into the vehicle reservoir tank from the radiator sometimes spills out of the overflow port of the vehicle reservoir tank. This can result in a low level of coolant in the cooling circuit as well as a mess in the engine compartment. If the coolant level in the cooling circuit gets too low, a thermal incident may eventually occur when operating the vehicle. Moreover, if the coolant is not cleaned up from the engine compartment after a coolant spill, an undesirable coolant odor may become prevalent in the vehicle passenger compartment.

In view of the above, it will be apparent to those skilled in the art from this disclosure that there exists a need for an improved vehicle reservoir tank. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a vehicle reservoir tank that prevents unnecessary spilling of fluid from the vehicle reservoir tank during filling of the vehicle cooling circuit (e.g., the radiator, engine water jacket, etc.).

In view of the above, a vehicle reservoir tank in accordance with one aspect of the present invention was developed in order to achieve the above mentioned object and other objects of the present invention. The vehicle reservoir tank of this aspect of the present invention basically comprises first and second end walls, first and second side walls, upper and lower walls, and a projection. A fluid port is formed in a lower end of the first end wall. The first and second side walls extend between the first and second end walls to form a substantially rectangular configuration. The upper and lower walls extend between the first and second end walls and the first and second side walls to form a main reservoir chamber with an overflow port formed in the upper wall adjacent the second end wall. The projection extends into the main reservoir chamber from one of the lower wall and the second end wall. The projection is configured and arranged to redirect a fluid flowing into the main reservoir chamber from the fluid port in a direction away from the overflow port.

These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a simplified schematic view of a vehicle with a vehicle reservoir tank in accordance with the present invention;

FIG. 2 is an enlarged, perspective view of the vehicle reservoir tank illustrated in FIG. 1 in accordance with the present invention;

FIG. 3 is a side elevational view of the vehicle reservoir tank illustrated in FIG. 2 in accordance with the present invention, with the flow of fluid into the tank identified with phantom lines for the purpose of illustration;

FIG. 4 is an end elevational view of the vehicle reservoir tank illustrated in FIGS. 2 and 3 in accordance with the present invention; and

FIG. 5 is a longitudinal cross-sectional view of the vehicle reservoir tank illustrated in FIGS. 2-4 in accordance with the present invention, as seen along section line 5-5 of FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A preferred embodiment of the present invention will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following description of the embodiment of the present invention is provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to FIG. 1, a vehicle 10 is schematically illustrated with a vehicle reservoir tank 12 in accordance with a preferred embodiment of the present invention. The vehicle reservoir tank 12 is arranged in a cooling circuit of the vehicle 10 in accordance with the present invention. The cooling circuit of the vehicle 10 basically includes the vehicle reservoir tank 12, a radiator 14, a coolant path (water jacket) 16 within an engine 18 and a coolant (water) pump 20 as well as other components. Basically, the water pump 20 forces the coolant to circulate within the cooling circuit. A temperature operated valve or thermostat 22 is disposed within the coolant path 16 of the engine 18 to selectively circulate the coolant through the radiator 14. The reservoir tank 12 supplies coolant to the radiator 14 and receives coolant from the radiator 14 via a conduit or hose 24. The reservoir tank 12 normally stores a predetermined amount of coolant in the interior when the vehicle 10 is parked. The various components of the cooling circuit, except for the vehicle reservoir tank 12, are conventional components. Thus, these conventional components will not be discussed and/or illustrated in detail herein.

Referring now to FIG. 2, the vehicle reservoir tank 12 is fixedly coupled to an inner wall 10 a of the vehicle 10 in a conventional manner, e.g. via a fastener 26, as discussed below. The vehicle reservoir tank 12 basically includes a main reservoir portion 30 defining an internal main reservoir chamber C therein, an overflow portion 32 and a mounting bracket 34. The overflow portion 32 includes an anti-spill chamber 36 in fluid communication with the main reservoir chamber C and an overflow channel 38 in fluid communication with the anti-spill chamber 36. Thus, the anti-spill chamber 36 is fluidly disposed between the main reservoir chamber C and the overflow channel 38.

The main reservoir portion 30 and the overflow portion 32 of the reservoir tank 12 are preferably integrally formed together as a one-piece, unitary member from a molded plastic material to form the main reservoir chamber C, the anti-spill chamber 36 and the overflow channel 38. On the other hand, the mounting bracket 34 is preferably formed as a separate member from the main reservoir portion 30 and the overflow portion 32. The mounting bracket 34 is coupled to a side of the main reservoir portion 30, and secures the vehicle reservoir tank 12 to the inner wall 10 a of the vehicle 10, as explained below in more detail.

The anti-spill chamber 36 and the overflow channel 38 form a continuous fluid passage that is fluidly connected to (in fluid communication with) the main reservoir chamber C such that coolant can exit the main reservoir chamber C via the anti-spill chamber 36 and the overflow channel 38 in the event the coolant level in the main reservoir portion 30 exceeds the maximum capacity of the main reservoir portion 30. Specifically, the anti-spill chamber 36 is fluidly connected to the main reservoir chamber C, while the overflow channel 38 is fluidly connected to the anti-spill chamber 36. The anti-spill chamber 36 and the overflow channel 38 are externally coupled to an upper end of the main reservoir portion 30.

As best seen in FIGS. 2-5, the main reservoir portion 30 basically includes first and second end walls 40 and 42, first and second side walls 44 and 46, upper and lower walls 48 and 50, and a projection 52 extending into the main reservoir chamber C from one of the lower wall 50 and the second end wall 42 that is configured and arranged to redirect a fluid flowing into the main reservoir chamber C, as explained below.

The first and second end walls 40 and 42 are preferably substantially parallel, vertically extending walls with a fluid inlet/outlet port 40 a formed in a lower end of the first end wall 40. The first and second side walls 44 and 46 are preferably substantially parallel vertically extending walls that extend between the first and second end walls 40 and 42 to form a substantially rectangular configuration. The first side wall 44 has protruding section that extends outwardly therefrom, as best seen in FIGS. 2 and 4. The upper and lower walls 48 and 50 are preferably substantially parallel horizontal walls that extend between the first and second end walls 40 and 42 and the first and second side walls 44 and 46 to form the main reservoir chamber C. The upper wall 48 includes a first substantially horizontal section 48 a extending from the first end wall 40, a second substantially horizontal section 48 b extending from the second end wall and a substantially vertical section 48 c extending between the first and second substantially horizontal sections 48 a and 48 b to form a step-shaped configuration. An overflow port 48 d is formed in the upper section 48 b of the upper wall 48 adjacent the second end wall 42.

The projection 52 preferably extends into the main reservoir chamber C from the lower wall 50. Specifically, the lower wall 50 preferably includes a lower section 50 a extending from the first end wall 40 and a sloped section 50 b extending upwardly from the lower section 50 a to the second end wall 42. Preferably, the projection 52 extends into the main reservoir chamber C from the sloped section 50 b of the lower wall 50. The lower section 50 a is substantially perpendicular to the walls 40, 42, 44 and 46, while the sloped section 50 b is preferably inclined about thirty degrees relative to the lower section 50 b. In any case, the projection 52 is configured and arranged to redirect a fluid flowing into the main reservoir chamber C from the fluid inlet/outlet port 40 a in a direction away from the overflow port 48 d, as explained below in more detail.

The inlet/outlet port 40 a has one end of the hose 24 mounted thereto in a conventional manner, while the other end of the hose 24 is mounted to the radiator 14 in a conventional manner such that main reservoir chamber C of the vehicle reservoir tank 12 is in fluid communication with the radiator 14. Thus, the vehicle reservoir tank 12 can supply coolant to the radiator 14 via the hose 24 and receive coolant from the radiator 14 via the hose 24. The inlet/outlet port 40 a acts as an inlet port when the vehicle reservoir tank 12 receives coolant from the radiator 14 via the hose 24. On the other hand, the inlet/outlet port 40 a acts as an outlet port when the vehicle reservoir tank 12 supplies coolant to the radiator 14 via the hose 24. The inlet/outlet port 40 a is preferably substantially parallel to the lower section 50 a, and arranged at the lower end of the first end wall 40 adjacent the lower section 50 a.

During filling of the entire cooling circuit (i.e., the radiator, engine water jacket, etc.), the inlet/outlet port 40 a acts as an inlet port, which receives coolant under relatively high pressure from the radiator 14 via the hose 24. The entire cooling circuit (i.e., the radiator, engine water jacket, etc.) is typically filled with relatively high pressure coolant via a fill opening in the radiator 14 at the time of manufacture of the vehicle 10 and/or after flushing or replacing the cooling circuit. In any case, when the cooling circuit is filled with high pressure coolant, the high pressure coolant will flow through the inlet/outlet port 40 a into the main reservoir chamber C. When this high pressure fluid flows into the main reservoir chamber C, the projection 52 redirects the coolant flowing into the main reservoir chamber C from the fluid inlet/outlet port 40 a in a direction away from the overflow port 48 d. In other words, the flow of fluid is not aligned with the overflow port 48 d, but rather extends in a transverse direction relative to a center axis of the overflow port 48 d after encountering the projection 52, as best understood from FIG. 3.

Referring still to FIGS. 2-5, the projection 52 is at least partially formed by a depression in one of the lower wall 50 and the second end wall 42. Preferably, the projection 52 is formed in the sloped section 50 b of the lower wall 50 adjacent the second end wall 42, as best seen in FIGS. 3-5. Thus, the projection 52 is preferably located closer to the second end wall 42 than the first end wall 40. The projection 52 preferably extends along a majority of a width of the main reservoir chamber C tank as measured between interior surfaces of the first and second side walls 44 and 46, as best understood from FIG. 4. The projection 52 preferably extends into the main reservoir chamber C by an amount such that the projection 52 overlaps the overflow port 48 d as viewed perpendicularly to the upper wall 48. The projection 52 is preferably disposed about halfway between a lowermost horizontal surface 50 c of the main reservoir chamber C and an uppermost horizontal surface 48 e of the main reservoir chamber C. The lowermost horizontal surface 50 c of the main reservoir chamber C is the interior surface of the lower section 50 a, while the uppermost horizontal surface 48 e of the main reservoir chamber C is the interior surface of the second substantially horizontal section 48 b.

The projection 52 basically includes a redirecting surface 52 a, a concave transition surface 52 b and a connecting surface 52 c. The redirecting surface 52 a extends generally perpendicular to the sloped section 50 b of the lower wall 50. The concave transition surface 52 b interconnects one end of the redirecting surface 52 a to an interior surface of the sloped section 50 b of the lower wall 50, while the connecting surface 52 c interconnects another end of the redirecting surface 52 a to an interior surface of the main reservoir chamber C. The connecting surface 52 c includes a horizontal section and a convex section as best seen in FIG. 5. The redirecting surface 52 a, the concave transition surface 52 b and the connecting surface 52 c preferably extend along the entire width of the projection 52 such that the projection 52 has a constant interior cross-sectional shape along its entire width. Externally of the main reservoir chamber C, the projection 52 includes a central flange 52 d formed therewith, as best seen in FIGS. 3-5.

Referring again to FIGS. 2-5, the main reservoir portion 30 further includes a reservoir filling opening 48 f, which can be selectively opened and closed using a removable reservoir cap 48 g. The reservoir filling opening 48 f is formed in the second substantially horizontal section 48 b of the upper wall 48 in a spaced arrangement from the overflow port 48 d. The main reservoir filling opening 48 f can be used to add additional coolant to the main reservoir tank 12, and thus, to add additional coolant to the cooling circuit if the level (amount) of coolant within the cooling circuit gets too low. The second sidewall 46 of the main reservoir portion 30 preferably includes a fluid level indicator 46 a located in the appropriate area to indicate a maximum fluid level and a minimum fluid level. The projection 52 preferably at least partially vertically overlaps with the “max” coolant indicator line of the fluid level indicator 46 a, as best understood from FIG. 3.

The overflow port 48 d and the reservoir filling opening 48 f are disposed at an uppermost portion of the main reservoir portion 30, while the fluid inlet/outlet port 40 a is disposed at a lowermost portion of the main reservoir portion 30. The overflow port 48 d has the anti-spill chamber 36 and overflow channel 38 in fluid communication therewith. In other words, the overflow portion 32 of the vehicle reservoir tank 12 is attached to the main reservoir portion 30 at the overflow port 48 d. The fluid inlet/outlet port 40 a has a tubular projection that is configured to attach to the hose 24 thereto. The hose 24 is clamped onto the tubular projection of the fluid inlet/outlet port 40 a by a clamp in a conventional manner. The reservoir cap 48 g is configured to close the reservoir filling opening 48 f when installed thereon (e.g., by a threaded connection or the like).

The main reservoir portion 30 is a two-tiered structure that includes a large lower tier section and a small upper tier section. The anti-spill chamber 36 is disposed at the upper tier section. The anti-spill chamber 36 is further disposed at a corner of the main reservoir portion 30. The fluid inlet/outlet port 40 a is disposed at an opposite corner of the main reservoir portion 30 on the lower tier section. Preferably, the anti-spill chamber 36 is located on the uppermost portion of the main reservoir portion 30 adjacent to the reservoir filling opening 48 f.

The configuration of the present invention described and illustrated herein reduces or eliminates coolant flowing out of the overflow port 48 d, through the anti-spill chamber 36 and out of the overflow chamber flow when the cooling circuit is filled with high pressure coolant.

Referring still to FIGS. 3-5, the anti-spill chamber 36 of the overflow portion 32 is configured and arranged to restrict the flow of fluid. Specifically, the anti-spill chamber 36 restricts the flow of fluid from the overflow port 48 d into the overflow channel 38, and thus restrict the flow of fluid to an area externally of the vehicle reservoir tank 12. More specifically, the anti-spill chamber 36 can collect fluid therein before flowing out of the overflow channel if the vehicle is tilted during transport or later driving.

As best seen in FIGS. 2-4, the mounting bracket 34 extends substantially perpendicularly from the end of the main reservoir portion 30 that has the overflow portion 32. The mounting bracket 34 basically includes a first fixed section 60 and a second fixed section 62. The first fixed section 60 is fixedly coupled to the main reservoir portion 30 at the second end wall 42. The first fixed section 60 supports the second fixed section 62 at its free end in a cantilevered manner. The second fixed section 62 is preferably attached to the inner wall 10 a of the vehicle 10. Preferably, the second fixed section 62 is secured to the inner wall 10 a by the fastener 26 that can include for example a bolt 64 and a nut 66. It will be apparent to one of ordinary skill in the art from this disclosure that the fixed section 62 can be attached to the inner wall 10 a in a variety of ways as needed and/or desired for the particular vehicle.

Referring to FIG. 3, the mounting bracket 34 also extends substantially perpendicularly to one side (i.e. the second side wall 46) of the main reservoir portion 30 such that a portion of the mounting bracket 34 is offset outwardly from the main reservoir portion 30. The bolt 64 extends through a through hole 62 a of the second fixed section 62 of the mounting bracket 34. In the illustrated embodiment, the mounting bracket 34 is a separate member from the main reservoir portion 30 that is mechanically attached to the main reservoir portion 30. In particular, the main reservoir portion 30 has a recess on its end wall that retains a first end portion of the first fixed section 60 via a snap-fit arrangement. The mounting bracket 34 can be made of metal, plastic or any other rigid material as needed and/or desired. Alternatively, the first fixed section 60 can be attached to the main reservoir portion 30 by adhesive or the like. It will be apparent to one of ordinary skill in the art from this disclosure that the mounting bracket 34 can be integrally molded with the main reservoir portion 30 if needed and/or desired.

As used herein, the following directional terms “forward, rearward, above, downward, vertical, horizontal, below and transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the present invention. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the present invention. The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. For example, these terms can be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies.

While only preferred embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing description of the embodiments according to the present invention is provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. Thus, the scope of the invention is not limited to the disclosed embodiments. 

1. A vehicle reservoir tank comprising: first and second end walls with a fluid port formed in a lower end of the first end wall; first and second side walls extending between the first and second end walls to form a substantially rectangular configuration; upper and lower walls extending between the first and second end walls and the first and second side walls to form a main reservoir chamber with an overflow port formed in the upper wall adjacent the second end wall; and a projection extending into the main reservoir chamber from one of the lower wall and the second end wall, the projection being configured and arranged to redirect a fluid flowing into the main reservoir chamber from the fluid port in a direction away from the overflow port.
 2. The vehicle reservoir tank according to claim 1, wherein the projection extends into the main reservoir chamber from the lower wall.
 3. The vehicle reservoir tank according to claim 1, wherein the lower wall includes a lower section extending from the first end wall and a sloped section extending upwardly from the lower section to the second end wall, and the projection extends into the main reservoir chamber from the sloped section of the lower wall.
 4. The vehicle reservoir tank according to claim 3, wherein the projection includes a redirecting surface extending generally perpendicular to the sloped section of the lower wall.
 5. The vehicle reservoir tank according to claim 4, wherein the projection includes a concave transition surface interconnecting one end of the redirecting surface to an interior surface of the sloped section of the lower wall.
 6. The vehicle reservoir tank according to claim 5, wherein the projection includes a connecting surface interconnecting another end of the redirecting surface to an interior surface of the main reservoir chamber.
 7. The vehicle reservoir tank according to claim 1, wherein the projection is at least partially formed by a depression in one of the lower wall and the second end wall.
 8. The vehicle reservoir tank according to claim 1, wherein the projection is disposed about halfway between a lowermost horizontal surface of the main reservoir chamber and an uppermost horizontal surface of the main reservoir chamber.
 9. The vehicle reservoir tank according to claim 8, wherein the projection is located closer to the second end wall than the first end wall.
 10. The vehicle reservoir tank according to claim 1, wherein the projection is located closer to the second end wall than the first end wall.
 11. The vehicle reservoir tank according to claim 1, wherein the upper wall further includes a fill opening spaced from the overflow port with a removable cap covering the fill opening.
 12. The vehicle reservoir tank according to claim 1, wherein the projection extends into the main reservoir chamber by an amount such that the projection overlaps the overflow port as viewed perpendicularly to the upper wall.
 13. The vehicle reservoir tank according to claim 12, wherein the lower wall includes a lower section extending from the first end wall and a sloped section extending upwardly from the lower section to the second end wall.
 14. The vehicle reservoir tank according to claim 13, wherein the projection includes a redirecting surface extending generally perpendicular to the sloped section of the lower wall.
 15. The vehicle reservoir tank according to claim 1, wherein the projection extends along a majority of a width of the main reservoir chamber as measured between interior surfaces of the first and second side walls.
 16. The vehicle reservoir tank according to claim 15, wherein the projection is at least partially formed by a depression in one of the lower wall and the second end wall.
 17. The vehicle reservoir tank according to claim 1, wherein the upper wall includes an anti spill chamber externally coupled to the overflow port of the main reservoir chamber to restrict fluid flowing out of the overflow port from the main reservoir chamber.
 18. The vehicle reservoir tank according to claim 1, wherein the upper wall includes a first substantially horizontal section extending from the first end wall, a second substantially horizontal section extending from the second end wall and a substantially vertical section extending between the first and second substantially horizontal sections to form a step-shaped configuration. 